Method and System of Valve Refurbishment

ABSTRACT

A valve assembly is disclosed with a housing having generally collinear inlet and outlet ports in the side walls thereof and an interior annular face about each of the inlet and outlet ports. The housing is made of a first metal with a yield strength. The assembly also has a chamber disposed between the inlet and outlet ports, wherein a vertical axis of the chamber is normal to longitudinal axes of the inlet and outlet ports. An annular groove is disposed about the interior annular face of the inlet port and the interior annular thee of the outlet port. A second metal is disposed within each of the annular grooves, the second metal having a yield strength greater than the yield strength of the first metal.

FIELD OF THE INVENTION

The present invention relates to valves and more particularly to animproved method and system of refurbishing high pressure valves thathave been subjected to extreme wear.

BACKGROUND OF THE INVENTION AND RELATED ART

Valves, including plug valves, have been used as a means for reliableflow isolation in high pressure flow line applications. Problems,however, exist with respect to the sealing capability of these deviceswhen used in connection with fluids containing abrasive materials. Thepresent invention relates to the sealing problems at the interface ofthe rotatable member found in such valves and their respective valveseats.

Prior attempts to seal the interface between the rotatable member andseats found in plug valves have included placement of O-rings withingrooves located in the face of the plug or the body of the valve itselfThe O-ring design, as well as reliance on other gasket-type sealingdevices, results in valve seal failure when used in high pressureenvironments (e.g., 10,000 to 15,000 psi) containing abrasive matter.Industry standards require that valves used in high pressureapplications operate within permissible pressure ranges with minimalpermissible levels of leakage. When operating in a high pressureenvironment, abrasive materials, such as sand, abrade the inner surfaceof the valve body and plug, including any grooved areas. As the innersurface is abraded, the interference fit between the valve and valveseats is decreased thereby lessening the sealing capability of thevalve. Valves must be tested on a regular basis and if they do not passinspection, they must be replaced resulting in undesirable costs andlost work hours and efficiency during the replacement of the valve.

A need exists, therefore, for improved systems and methods for valverefurbishment and/or strengthening of valves to improve the sealingfunction and decrease maintenance costs and lost time associated withvalve failure.

SUMMARY OF THE INVENTION

In light of the problems and deficiencies inherent in the prior art, thepresent invention seeks to overcome these by providing a valve assemblywith a strengthened inner wall. In accordance with one embodiment of theinvention, a valve assembly is disclosed comprising a housing havinggenerally collinear inlet and outlet ports in the side wails thereof andan interior annular face about each of the inlet and outlet ports, thehousing comprising a first metal with a yield strength. A chamber isdisposed between the inlet and outlet ports, wherein a vertical axis ofthe chamber is normal to longitudinal axes of the inlet and outletports. A sealing member is disposed within the chamber and an annulargroove is disposed about the interior annular face of the inlet port andoutlet port. A second metal disposed within each of the annular grooves,the second metal having a yield strength greater than the yield strengthof the first metal.

In another embodiment of the present invention, a method of refurbishinga damaged valve is disclosed comprising receiving a damaged valveassembly, the valve assembly comprising a valve housing having generallycollinear inlet and outlet ports in the side walls thereof and aninterior annular face about each of the inlet and outlet ports, thehousing comprises o first metal with a yield strength and the side wallshaving a predetermined thickness. A chamber is disposed between theinlet and outlet ports, wherein the vertical axis of the chamber isnormal to longitudinal axes of the inlet and outlet ports and a sealingmember is disposed within the chamber having an axial bore therethrough.The method further comprises removing the sealing member from thechamber of the valve housing and creating a U-shaped substantiallysmooth annular groove about the interior annular face of the inlet port,wherein a horizontal axis of the U-shaped groove is normal to theinterior annular face of the inlet port. Additionally, the methodcomprises creating a U-shaped substantially smooth annular groove aboutthe interior annular face of the outlet port wherein a horizontal axisof the U-shaped groove is normal to the interior annular face of theoutlet port. The method also comprises heating the valve housing to atleast approximately 500 degrees Fahrenheit after creating said annulargrooves. Once heated, the method further comprises placing a secondmetal within each of the annular grooves, the second metal having ayield strength greater than the yield strength of the first metal, Afterdepositing the second metal in the groove, the method comprises heatingthe valve housing to at least 950 degrees Fahrenheit for approximatelyone hour per inch of the predetermined side wall thickness, allowing thevalve housing to cool and placing the sealing member into the chamberafter step.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully apparent from the followingdescription and appended claims, taken in conjunction with theaccompanying drawings. Understanding that these drawings merely depictexemplary embodiments of the present invention they are, therefore, notto be considered limiting of its scope. It will be readily appreciatedthat the components of the present invention, as generally described andillustrated in the figures herein, could be arranged and designed in awide variety of different configurations. Nonetheless, the inventionwill be described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 is a side cross-sectional view of a valve assembly in accordancewith one embodiment of the invention;

FIG. 2 is a side cross-sectional view of a valve body in accordance withone embodiment of the invention;

FIG. 3 is a side cross-sectional view of a valve body in accordance withone embodiment of the invention;

FIGS. 4 a through 4 d are a side cross-sectional views of a surface of avalve body in accordance with one embodiment of the invention; and

FIG. 5 is a side cross-sectional view of a valve body in accordance withone embodiment of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following detailed description of exemplary embodiments of theinvention makes reference to the accompanying drawings, which form apart hereof and in which are shown, by way of illustration, exemplaryembodiments in which the invention may be practiced. While theseexemplary embodiments are described in sufficient detail to enable thoseskilled in the art to practice the invention, it should be understoodthat other embodiments may be realized and that various changes to theinvention may be made without departing from the spirit and scope of thepresent invention. Thus, the following more detailed description of theembodiments of the present invention is not intended to limit the scopeof the invention, as claimed, but is presented for purposes ofillustration only and not limitation to describe the features andcharacteristics of the present invention, to set forth the best mode ofoperation of the invention, and to sufficiently enable one skilled inthe art to practice the invention. Accordingly, the scope of the presentinvention is to be defined solely by the appended claims.

The following detailed description and exemplary embodiments of theinvention will be best understood by reference to the accompanyingdrawings, wherein the elements and features of the invention aredesignated by numerals throughout.

The present invention describes an improved method and system of highpressure valve refurbishment and/or manufacture. The improved systemresults in decreased wear and improved resistance to abrasion whencontrolling the flow of fluids in high pressure systems containingabrasive materials such as sand. It is intended that the method andresulting valve assembly devices of the present invention be operablewith different types of materials and valve configurations so long asthe end result of improved sealing is achieved. Bearing that in mind,the valve assembly of the present invention, in accordance with oneaspect of the invention, may be broadly described as a housing havinggenerally collinear inlet and outlet ports in the side walls thereof andan interior annular face about each of the inlet and outlet ports. Thehousing is made of a first metal such as steel with a pre-determinedyield strength. A chamber is located between the inlet and outlet ports.A vertical axis of the chamber is normal to longitudinal axes of theinlet and outlet ports and a sealing member disposed within the chamber.In one aspect of the invention, the sealing member is a cylindrical plugwith an axial bore therethrough. An annular groove is disposed about theinterior annular face of the inlet and outlet ports. A second metal isdisposed within each of the annular grooves. The second metal has apre-determined yield strength higher than the yield strength of thefirst metal.

The present invention is intended to be operable with numerous valveconfigurations and has particular application in the refurbishment ofvalves used in to regulate flow of abrasive materials in high-pressureenvironments. Referring now specifically to the figures with referenceto one exemplary embodiment, a valve assembly 10 is generally shown inFIG. 1. The valve 10 has a housing 11, and ported plug valve sealingmember 12 rotatable relative to the housing 11 and positioned betweeninlet port 15 and an outlet port 16.

With reference generally to FIGS. 1 through 3, the housing 11 contains acylindrical bore with cylindrical side walls 17 and a bottom wall 18defining a valve chamber 19. The top of the chamber is closed by meansof a flange member held in position by threaded cap screws or an acmescrewed lid with mating threads in the body. Positioned within thisvalve chamber is the rotatable valve sealing member 12 having a port 21extending therethrough. Extending from the top of the valve sealingmember 12 in a wrench head extension with a threaded portion, wherebythe valve member 12 can have the you 21 thereof rotated into and out ofregister with the inlet and outlet ports 15 and 16, respectively. Inthis manner, as the valve member 12 is rotated, port 21 provides a meanswhereby fluid may be transferred from the inlet port 15 through theoutlet port 16. While the interior of the valve chamber 19 iscylindrical, the inlet port 15 and outlet port 16 have a flat interiorannular face.

The housing 11 of the valve assembly 10 can be made of a steel alloy asis known in the art having a yield strength ranging from 75,000 to115,000 pounds per square inch and tensile strength ranging from 95,000to 150,000 pounds per square inch. While steel is specificallyreferenced herein, other metal alloys may be used to suit a particularpurpose.

In some instances an O-ring made of a resilient material (such asrubber) is located on the valve member 12 about the annular face of port21. In other instances, an O-ring is located about the interior annularface of inlet port 15 and outlet port 16. When operating the valveassembly in high-pressure (e.g., 8,000 to 18,000 pounds per square inch)environments, abrasive materials such as sand abrades the areas aboutthe interior annular face of the inlet port 15 and outlet port 16 (seee.g., FIG. 4 a) reducing the ability of the valve member 12 toeffectively operate as a seal when the port 21 is rotated out ofregister with the inlet and outlet ports 15,16.

With reference now generally to FIGS. 1-5, in the event a valve assembly10 fails a pressure test, the valve has conventionally been thrown awayand replaced resulting in unwanted expenditures. A method has beendevised of refurbishing valves damaged in this manner comprisingreceiving a damaged valve assembly as described herein and removing thevalve sealing member 12 from the chamber 19 of the valve housing 11. AU-shaped, substantially smooth, annular groove 30 is machined about theinterior annular face 20 of the inlet port 15 and outlet port 16, Alongitudinal axis of the U-shaped groove 30 is normal to the flatsurface of the interior annular face 20 of the inlet and outlet ports15,16. In one aspect of the invention, the U-shaped groove comprisessubstantially parallel side walls with a curvilinear bottom, much like aU. In another aspect of the invention, the U-shaped groove comprises amore open U shape with curvilinear side walls and a curvilinear bottom.In this aspect, the “open-faced” U creates a larger surface area forrefurbishment with a more shallow groove. In any event, the smoothU-shaped groove provides an even surface that is better suited toreceive and bond with the second metal 31.

In accordance with one aspect of the invention, the specific geometry ofthe U-shaped grooves range from approximately 0.2 to 0.4 inches wide andapproximately 0.1 to 0.2 inches deep. While a U-shaped geometry isreferenced as a preferred embodiment, it is understood that other shapedgrooves are contemplated for use herein including, but withoutlimitation, V-shaped grooves or rectangular-shaped grooves.

Once the U-shaped groove 30 is machined into the interior annular face20 of the inlet and outlet ports, the valve housing 11 is heated fromapproximately 400 to 600 degrees Fahrenheit. While maintaining thetemperature of the valve housing, a second metal 31 is placed withineach of the annular grooves. In one aspect of the invention, the secondmetal 31 completely fills the U-shaped groove and exceeds the capacityof the groove extending outside the upper surface of the interiorannular face 20 of the inlet port and outlet port.

After the second metal 31 is placed within the annular groove 30, thevalve housing 11 is heated to a temperature ranging from approximately950 to 1200 degrees Fahrenheit for approximately one hour of every inchof thickness of the side wall of the valve housing. Advantageously, theheating and cooling process increases the resistance to brittle fractureand relaxes residual stresses in the heat affected zone at the bondingpoint of the original base metal and the second material beingdeposited. Once the heating process is complete, the valve housing 11 isallowed to cool and the area about the annular grooves 30 is machined sothat the top surface 33 of the second metal 31 within the grooves iscoplanar with the surrounding interior annular face 20 of the inlet andoutlet ports.

In accordance with one aspect of the invention, the second metal 31 isplaced within the annular grooves 30 by a welding process such as SMAW(shielded metal arc welding), MIG (metal arc-inert gas), TIG (tungstenarc-inert gas). In accordance with one aspect of the invention, thesecond metal 31 may be a welding rod which is disposed in the groove asa weld bead filling the entire groove with the second metal 31, Inaccordance with one embodiment, the weld bead is deposited within thegroove such that the height of the bead is greater than the depth of thegroove spilling out over the side edges of the groove (see e.g., FIG. 4c). At the termination of the heating/cooling cycle referenced above,any weld bead that was outside the U-shaped groove is machined to createa smooth transition from the groove to the interior annular face of theinlet and/or outlet ports such that the top of the second metal issubstantially coplanar with the interior annular face of the inletand/or outlet ports (see e.g., FIG. 4 d).

In accordance with one embodiment of the invention, the second metal 31comprises an alloy containing at least nickel, chromium, cobalt, andmolybdenum having a. yield strength ranging from 75,000 to 115,000pounds per square inch and a tensile strength ranging from 95,000 to150,000 pounds per square inch. In one aspect of the invention, thealloy comprises at least 60 to 70 percent nickel, 20 to 25 percentchromium, 7 to 11 percent molybdenum, and 10 to 12 percent cobalt. Othermaterials for the second metal may also be used and fall within thespirit of the invention described herein, including alloys containingcarbon steel, copper, phosphorus, sulfur, aluminum, silicon, iron, andmagnesium.

The foregoing detailed description describes the invention withreference to specific exemplary embodiments. However, it will beappreciated that various modifications and changes can be made withoutdeparting from the scope of the present invention as set forth in theappended claims. The detailed description and accompanying drawings areto be regarded as merely illustrative, rather than as restrictive, andall such modifications or changes, if any, are intended to fail withinthe scope of the present invention as described and set forth herein.

More specifically, while illustrative exemplary embodiments of theinvention have been described herein, the present invention is notlimited to these embodiments, but includes any and embodiments havingmodifications, omissions, combinations (e.g., of aspects across variousembodiments), adaptations and/or alterations as would be appreciated bythose in the art based on the foregoing detailed description. Thelimitations in the claims are to be interpreted broadly based on thelanguage employed in the claims and not limited to examples described inthe foregoing detailed description or during the prosecution of theapplication, which examples are to be construed as non-exclusive. Forexample, in the present disclosure, the term “preferably” isnon-exclusive where it is intended to mean “preferably, but not limitedto.” Any steps recited in any method or process claims may be executedin any order and are not limited to the order presented in the claims.Means-plus-function or step-plus-function limitations will only beemployed where for a specific claim limitation all of the followingconditions are present in that limitation: a) “means for” or “step for”is expressly recited; and b) a corresponding function is expresslyrecited. The structure, material or acts that support themeans-plus-function are expressly recited in the description herein.Accordingly, the scope of the invention should be determined solely bythe appended claims and their legal equivalents, rather than by thedescriptions and examples given above.

1. A valve assembly, comprising: a housing having generally collinearinlet and outlet ports in the side walls thereof and an interior annularface about each of the inlet and outlet ports, the housing comprising afirst metal with a yield strength; a chamber disposed between the inletand outlet ports, wherein a vertical axis of the chamber is normal tolongitudinal axes of the inlet and outlet ports; a sealing memberdisposed within the chamber; an annular groove disposed about theinterior annular face of the inlet port; an annular groove disposedabout the interior annular face of the outlet port; and a second metaldisposed within the each of the annular grooves, the second metal havinga yield strength, wherein the yield strength of the first metal is lessthan the yield strength of the second metal.
 2. The valve assembly ofclaim 1, wherein the annular groove disposed about the interior annularface of the inlet port and the annular groove disposed about theinterior annular face of the outlet port is U-shaped.
 3. The valveassembly of claim 2, wherein the annular groove disposed about theannular face of the outlet port circumscribes the outlet port and theannular groove disposed about the annular face of the inlet portcircumscribes the inlet port.
 4. The valve assembly of claim 1, whereinthe yield strength of the first metal ranges from 75,000-115,000 poundsper square inch.
 5. The valve assembly of claim 1, wherein the yieldstrength of the second metal ranges from 95,000 to 150,000 pounds persquare inch.
 6. The valve assembly of claim 1, wherein the first metalcomprises steel and the second metal comprises a nickel alloy.
 7. Thevalve assembly of claim 1, wherein a top surface of the second metalwithin the annular groove about the interior annular face of the inletport is co-planar with the annular face of the inlet port and a topsurface of the second metal within the annular groove about the interiorannular face of the outlet port is co-planar with the annular face ofthe outlet port.
 8. A method, comprising: (a) receiving a valve housinghaving generally collinear inlet and outlet ports in the side wallsthereof and an interior annular face about each of the inlet and outletports, the housing comprising a first metal with a yield strength andthe side walls having a predetermined thickness; (b) creating an annulargroove about an interior annular face of the inlet port; (c) creating anannular groove about an interior annular face of the outlet port; (d)heating the valve housing to between approximately 400 and 600 degreesFahrenheit after creating said annular grooves; (e) placing a secondmetal within each of the annular grooves, the second metal having ayield strength, wherein the yield strength of the first metal is lessthan the yield strength of the second metal; and (f) after placing thesecond metal within each of the annular grooves, heating the valvehousing to between approximately 950 and 1200 degrees Fahrenheit forapproximately one hour per inch of the predetermined side wallthickness.
 9. The method of claim 8, wherein the temperature of thevalve housing is maintained at between approximately 400 and 600 degreesFahrenheit during placement of the second metal within each of theannular grooves.
 10. The method of claim 8, wherein the grooves have aU-shaped geometry.
 11. The method of claim 10, wherein the U-shapedgrooves are smooth.
 12. The method of claim 10, wherein the second metalis placed into the grooves by a welding process.
 13. The method of claim10, wherein the second metal comprises an alloy containing nickel,chromium, cobalt, and molybdenum.
 14. A method of refurbishing a damagedvalve, comprising: (a) receiving a damaged valve assembly, the valveassembly comprising: (i) a valve housing having generally collinearinlet and outlet ports in the side walls thereof and an interior annularface about each of the inlet and outlet ports, the housing comprising afirst metal with a yield strength and the side walls having apredetermined thickness; (ii) a chamber disposed between the inlet andoutlet ports, wherein the vertical axis of the chamber is normal tolongitudinal axes of the inlet and outlet ports; and (iii) a sealingmember disposed within the chamber having an axial bore therethrough;(b) removing the sealing member from the chamber of the valve housing;(c) creating a U-shaped substantially smooth annular groove about theinterior annular face of the inlet port after step (b), wherein ahorizontal axis of the U-shaped groove is normal to the interior annularface of the inlet port; (d) creating a U-shaped substantially smoothannular groove about the interior annular face of the outlet port afterstep (b), wherein a horizontal axis of the U-shaped groove is normal tothe interior annular face of the outlet port; (e) heating the valvehousing to approximately 500 degrees Fahrenheit after creating saidannular grooves; (f) after step (e), placing a second metal within eachof the annular grooves, the second metal having a yield strength,wherein the yield strength of the first metal is less than the yieldstrength of the second metal; and (g) after step (f), heating the valvehousing to at least 950 degrees Fahrenheit for approximately one hourper inch of the predetermined side wall thickness; (h) allowing thevalve housing to cool after step (g); and (i) placing the sealing memberinto the chamber after step (h).
 15. The method of claim 14, wherein aquantity of the second metal is placed within the area about each of theU-shaped grooves such that the height of the second metal within each ofthe U-shaped grooves is greater than the depth of the U-shaped grooves.16. The method of claim 15, wherein the second metal completely fillsthe U-shaped grooves.
 17. The method of claim 15, further comprising thestep of removing any portion of the second metal that is not within theU-shaped groove after the step recited in claim
 15. 18. The method ofclaim 15, wherein the yield strength of the second metal ranges from95,000 to 135,000 pounds per square inch.
 19. The method of claim 15,wherein the second metal is an alloy containing at least carbon steel oran alloy containing at least nickel and molybdenum.
 20. The method ofclaim 16, wherein a top surface of the second metal within the U-shapedgroove about the interior annular face of the inlet port is co-planarwith the annular face of the inlet port and a top surface of the secondmetal within the U-shaped groove about the interior annular face of theoutlet port is co-planar with the annular face of the outlet port.